Cleaning sponge made of viscose

ABSTRACT

The aim of the invention is to specify a cleaning sponge that can be produced without problems and that has a surface that is as dirt-repellent as possible yet absorbent. According to the invention, a cleaning sponge, composed of a plurality of layers ( 1, 2, 3 ) connected to each other, a first layer ( 1 ) being made of viscose and a second layer ( 2 ) being designed as a sponge that is made of a plastic, is characterized in that the first layer ( 1 ) has a first side ( 1   a ) and a second side ( 1   b ), the first side ( 1   a ) and/or the second side ( 1   b ) having a compressed film-like surface and the film-like surface having a higher density than the rest of the first layer ( 1 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is the national phase of PCT/EP2011/001418,filed Mar. 22, 2011 which claims the benefit of German PatentApplication No. 10 2010 034 193.2, filed Aug. 12, 2010.

FIELD OF THE INVENTION

The present invention relates to a cleaning sponge.

BACKGROUND OF THE INVENTION

Cleaning sponges including a plurality of layers connected to oneanother, with a first layer made of viscose and a second layer being asponge made of a synthetic material, are known from the prior art.

The first layer is constructed in the form of a so-called block-shapedviscose material which is discontinuously manufactured in blocks. In theprior-art manufacturing method used, viscose is produced in a number ofprocessing steps from cellulose using a xanthation reaction. The viscoseis mixed with sodium sulfate decahydrate, also known as Glauber's salt,which functions as a pore-forming agent, and is subsequently poured intoa mold. In a subsequent processing step, xanthate is decomposed. Thepore-forming agent is removed in the next processing step. This leads tothe formation of a sponge-like structure. Subsequently, the blocks arecut into viscose layers and further processed.

A disadvantage of this method is that cutting the blocks to form layersis time-consuming and requires a large number of handling steps. Thus,the production of layers made of block-shaped viscose is expensive andtime-consuming.

Another disadvantage is that cutting the blocks into layers createssurfaces with open or cut pores in which dirt can accumulate.

SUMMARY OF THE INVENTION

Accordingly, an object of the present invention is to provide a cleaningsponge which can be easily produced and which has a highlydirt-repellant, yet absorbent surface.

According to the present invention, a first layer has a first side and asecond side, with the first side and/or the second side having acompacted film-like surface and with the film-like surface having ahigher density than the rest of the first layer. The film-like surfaceprevents dirt particles from penetrating into the pores of the viscose.In addition, it also stabilizes the first layer. Viscose manufacturedusing a method for the continuous production of viscose sponges has theadvantage of having a film-like surface or skin. Block-shaped viscose,on the other hand, does not have such a film-like surface since it mustbe cut to size. A further advantage is that the first layer is durableand has a more hygienic appearance since it is nearly impossible fordirt to get stuck in the surface. A film-like surface has a positiveinfluence on the dirt retention of the first viscose layer.

Specifically, it was found that viscose manufactured using a method forthe continuous production of viscose sponges has the surfaces desired.The reason is that viscose manufactured by a method for the continuousproduction of viscose sponges is continuously deposited on a conveyerbelt, where it is spread out by a roller, and transported on theconveyer belt through a plurality of baths. In the course of thisprocess, the xanthate is decomposed and the pore-forming agent isremoved. This creates a sponge-like structure. Subsequently, a viscoselayer is finished with a film-like surface which provides the layer withdirt-repellant properties. Specifically, it was found that whenmanufacturing the first viscose layer using a method for the continuousproduction of viscose sponges, this layer requires cutting only in thelongitudinal direction and/or transverse direction, but not in thedirection of its thickness. It is therefore possible to produce thecleaning sponge with only a few handling steps. Thus, the inventionmakes available a cleaning sponge which can be easily manufactured andwhich has a highly dirt-repellant and, at the same time, an absorbentsurface.

The first side and/or the second side can have a contoured surface. Acontoured surface helps facilitate the pickup of dirt.

The first side could have a contoured surface that has nub-likeelevations. Nub-like elevations surprisingly release a relatively smallamount of water to a surface to be cleaned. It was also surprising todiscover that a side that has nub-like elevations or nubs releases asmaller amount of water than a side with linear elevations or grooves.

The first side could have a contoured surface that has linearelevations. Surprisingly, linear elevations release a larger amount ofwater to a surface to be cleaned than nub-like elevations. Yet, a sideof a first viscose layer manufactured by a method for the continuousproduction of viscose sponges and that has linear elevations stillreleases a smaller amount of water than a side made of block-shapedviscose. By way of an example, it was determined that viscosemanufactured by a method for the continuous production of viscosesponges releases 0.8 g/m² water while block-shaped viscose releases 1.2g/m². Therefore, a first layer of viscose manufactured by a method forthe continuous production of viscose sponges releases approximately 30%less water than a first layer made of block-shaped viscose.

The second side could have a contoured surface that has nub-likeelevations. The contoured surface facilitates bonding to the secondlayer since the adhesive interacts with the nub-like elevations in afusion-bonding and form-fitting manner.

The second side could have a contoured surface that has linearelevations. The contoured surface facilitates bonding to the secondlayer since the adhesive interacts with the linear elevations in afusion-bonding and form-fitting manner.

The second side could face the second layer. This would allow the firstlayer to be bonded to the second layer or to be laminated to it, withthe first side of the first layer not having a cover.

A third layer that includes an abrasive element could be provided. Thiswould make it possible to remove coarse caked-on dirt from a surfacethat is to be cleaned.

The abrasive element could be a fiber woven fabric. The fiber wovenfabric can be a textile fabric or a nonwoven. Nonwovens can be producedinexpensively and can be easily heat-sealed or bonded to a sponge madeof a synthetic material.

The abrasive element can take the form of a coating, in particular apolyurethane coating. A coating in the form of a pasty material can beapplied with a doctor blade, or it can be sprayed or spread-coated ontothe sponge. The coating can contain any particles that are sufficientlyhard so as to be able to remove dirt.

The first layer could have a density of 60 kg/m³. Block-shaped viscose,on the other hand, in most cases has a density of only 35 kg/m³.

The first layer is a preformed layer that could have a thickness ofapproximately 1 cm. A first layer produced from block-shaped viscose canhave any thickness since such a layer is cut from the block. Theadvantage of the cleaning sponge of the present invention is that thethickness is increased in that a second layer, i.e., the sponge, isattached. This sponge is preferably produced from polyurethane,polyester or polyether. The advantage is that the thickness is increasedwithout loss of the water-absorbing capacity. More specifically, thesponge acts as a spacer and stabilizes the cleaning sponge in such amanner that any potential shrinkage in the thickness, length and widthof the final product is reduced.

There are a number of possibilities to improve and further develop theteaching of the present invention to advantage. Thus, reference is madeto the following description of preferred practical examples of thecleaning sponge according to the present invention based on the attacheddrawings.

In conjunction with the description of the preferred practical examplesbased on the drawing, other generally preferred configurations andadvanced embodiments of the teaching of the invention will be describedas well.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, the upper portion in each of FIGS. 1-4 shows a top viewof a first layer made of viscose, and each lower portion shows asectional view of the cleaning sponge.

FIG. 1 includes in its upper portion a top view of a cleaning spongeaccording to the invention showing a first layer made of viscose and itslower portion a cross-sectional view of the cleaning sponge.

FIG. 2 includes in its upper portion a top view of another embodiment ofa cleaning sponge according to the invention showing a first layer madeof viscose and its lower portion a cross-sectional view of the cleaningsponge.

FIG. 3 includes in its upper portion a top view of another embodiment ofa cleaning sponge according to the invention showing a first layer madeof viscose and its lower portion a cross-sectional view of the cleaningsponge.

FIG. 4 includes in its upper portion a top view of another embodiment ofa cleaning sponge according to the invention showing a first layer madeof viscose and its lower portion a cross-sectional view of the cleaningsponge.

DETAILED DESCRIPTION OF THE INVENTION

The lower portion of FIG. 1 provides a sectional view of a cleaningsponge including a plurality of layers that are connected to oneanother, with a first layer 1 being made of viscose and a second layer 2being a sponge made of a synthetic material. The first layer 1 has afirst side 1 a and a second side 1 b, with at least one of the sides(i.e., side 1 a) having a contoured surface. The side 1 b is smooth.

The first side 1 a has a contoured surface that has linear elevations.These can be seen in the upper portion of FIG. 1. The first side 1 a hasa compacted film-like surface, with the film-like surface having ahigher density than the rest of the first layer 1. The second side 1 bfaces the second layer 2. A third layer 3 is also provided which has anabrasive element. The abrasive elements takes the form of a coating 3 a.

The lower portion of FIG. 2 provides a sectional view of a cleaningsponge including a plurality of layers that are connected to oneanother, with a first layer 1 being made of viscose and a second layer 2being a sponge that is made of a synthetic material. The first layer 1has a first side 1 a and a second side 1 b, with at least one of thesides having a contoured surface.

The first side 1 a has a contoured surface that has nub-like elevations.These can be seen in the upper portion of FIG. 2. The second side 1 bhas a contoured surface that has linear elevations. The first side 1 aand the second side 1 b have a compacted film-like surface, with thefilm-like surface having a higher density than the rest of the firstlayer 1. The second side 1 b faces the second layer 2. A third layer 3is also provided which includes an abrasive element. The abrasiveelement takes the form of a coating 3 a.

The lower portion of FIG. 3 provides a sectional view of a cleaningsponge including a plurality of layers that are connected to oneanother, with a first layer 1 being made of viscose and a second layer 2being a sponge made of a synthetic material. The first layer 1 has afirst side 1 a and a second side 1 b, with at least one of the sideshaving a contoured surface. The first side 1 a has a contoured surfacethat has nub-like elevations. These can be seen in the upper portion ofFIG. 3. The second side 1 b has a contoured surface that has linearelevations. The first side 1 a and the second side 1 b have a compactedfilm-like surface, with the film-like surface having a higher densitythan the rest of the first layer 1. The second side 1 b faces the secondlayer 2. A third layer 3 is also provided which includes an abrasiveelement. The abrasive element takes the form of a fiber-woven fabric 3b.

The lower portion of FIG. 4 shows a sectional view of a cleaning spongecomprising a plurality of layers that are connected to one another, witha first layer 1 being made of viscose and a second layer 2 being asponge made of a synthetic material. The first layer 1 has a first side1 a and a second side 1 b, with at least one of the sides (i.e., side 1a) having a contoured surface. The side 1 b is smooth. The first side 1a has a contoured surface that has linear elevations. These can be seenin the upper portion of FIG. 4. The first side 1 a has a compactedfilm-like surface, with the film-like surface having a higher densitythan the rest of the first layer 1. The second side 1 b faces the secondlayer 2. A third layer 3 is also provided that includes an abrasiveelement. The abrasive element takes the form of a fiber-woven fabric 3b.

In FIGS. 1-4, the sponge which constitutes the second layer 2 can bemade of polyester, polyurethane or polyether.

The first layer 1 is made of viscose that is manufactured using a methodfor the continuous production of viscose sponges. This first layer iscut in the longitudinal and/or transverse direction. In the z-direction,i.e., in the direction of its thickness, the first layer 1 is not cut,but preformed.

In FIGS. 1-4, the third layer 3 is disposed on the side of the secondlayer 2, which side faces away from the first layer 1. The second layer2 is sandwiched between the first layer 1 and the third layer 3.

Although not shown in FIGS. 1-4, it is possible for both the first side1 a and the second side 1 b to have a smooth surface, with the firstside 1 a and the second side 1 b having a compacted film-like surfaceand with the film-like surface having a higher density than the rest ofthe first layer 1.

As to additional useful configurations and advanced embodiments of theteaching according to the present invention, reference is made, on theone hand, to the general part of the description and, on the other hand,to the attached claims.

1-10. (canceled)
 11. A cleaning sponge comprising: a plurality of layersthat are connected to one another including a first layer being made ofviscose and a second layer being a sponge made of a synthetic material,wherein the first layer has a first side and a second side, with atleast one of the first side or the second side having a compactedfilm-like surface and with the film-like surface having a density higherthan a density of the rest of the first layer.
 12. The cleaning spongeas in claim 11, wherein at least one of the first side or the secondside of the first layer has a contoured surface.
 13. The cleaning spongeas in claim 11, wherein the first side of the first layer has acontoured surface that has nub-like elevations.
 14. The cleaning spongeas in claim 11, wherein the first side of the first layer has acontoured surface that has linear elevations.
 15. The cleaning sponge asin claim 11, wherein the second side of the first layer has a contouredsurface that has nub-like elevations.
 16. The cleaning sponge as inclaim 11, wherein the second side of the first layer has a contouredsurface that has linear elevations.
 17. The cleaning sponge as in claim11, wherein the second side of the first layer faces the second layer.18. The cleaning sponge as in claim 11, further comprising a third layerthat includes an abrasive element.
 19. The cleaning sponge as in claim18, wherein the abrasive element comprises a fiber-woven fabric.
 20. Thecleaning sponge as in claim 18, wherein the abrasive element comprises acoating.